Induction Heating Extension Cable With Isolated Control Conductors

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Solution Overview

Problem

In induction heating systems, it is challenging to efficiently deliver induction heating current over long distances while also enabling data and power transmission to remote monitoring devices, especially in environments where physical damage and electrical isolation are concerns.

Innovation Solution

The use of induction heating extension cables with integrated control conductors that are electrically isolated from the induction heating current-carrying conductors, allowing for data and power transmission within the outer protective layer of the cable, thereby addressing the need for efficient current delivery and remote monitoring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional cables are used to deliver induction heating current over long distances, then current delivery is achieved, but leakage increases and efficiency decreases

Engineering Contradiction:

ImproveleakageVSAvoiddistance

Core Design Contradiction:

Loss of energyVSLength of moving object

Solution Approach 1:

The cable is segmented into multiple tightly coupled conductors (Litz wire configuration) rather than using a single conductor. This segmentation reduces skin effect and proximity effect, minimizing leakage and improving current delivery efficiency over long distances

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple conductors are nested within each other in a tightly coupled configuration, with each conductor positioned within the magnetic field of the others. This nested arrangement enhances magnetic coupling and reduces leakage

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If separate control cables are used for data transmission, then data transmission is enabled, but device complexity and physical vulnerability increase

Engineering Contradiction:

Improvedata transmission capabilityVSAvoidcable structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The control conductors are merged with the power conductors within a single outer protective layer, creating an integrated cable assembly. This combines power delivery and data transmission functions into one unified structure, reducing complexity and physical vulnerability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cable assembly serves multiple functions simultaneously: delivering induction heating current through power conductors and transmitting control data through control conductors, all within a single protective envelope. This multi-functionality eliminates the need for separate cables

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If control conductors are electrically isolated from power conductors, then safety is improved, but cable design complexity increases

Engineering Contradiction:

Improveelectrical isolationVSAvoidcable design

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

An outer protective layer acts as an intermediary barrier between control conductors and power conductors. This protective layer provides electrical isolation and safety while maintaining a relatively simple cable design, avoiding the need for complex isolation structures

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution enhances the efficiency of induction heating by minimizing leakage and improving current delivery, while also enabling reliable data and power transmission to remote monitoring devices, even in physically demanding environments.

Implementation Method 1

induction heating current-carrying conductors (e.g., in a Litz cable arrangement)

Methodology Applied

Scientific EffectElectromagnetic Induction: Electromagnetic Induction

Implementation Method 2

induction heating currents induce eddy currents within the workpiece

Methodology Applied

Scientific EffectEddy Currents: Eddy Currents

Implementation Method 3

an outer protective layer configured to protect the first plurality of conductors from physical damage

Methodology Applied

Scientific EffectPhysical Containment: Physical Containment

Data Source

PatentUS12273982B2Induction heating extension cables including control conductors

Publication Date: 2025.04.08 ILLINOIS TOOL WORKS INC

AI summary

Induction heating extension cables including control conductors are disclosed. An example cable assembly includes: a first plurality of conductors in a Litz cable arrangement; an outer protective layer configured to protect the plurality of conductors from physical damage; and a second plurality of conductors that are electrically isolated from the first plurality of conductors and are protected by the outer protective layer from physical damage.